VFanuc robot check: 4 Fanuc robots in session "default"

I only read the backups and changed nothing. This was a signal and data check of the backups, not a geometric check.

Comparison of the robots

Robot	Model / rated payload	Software / VW user	UT used	UF used	PAYLOAD used	Travel track	Errors	Warnings
K9GHNE203315R01	R-2000iB/210F, 210 kg	V7.6310, VW user –	1, 2	0, 1	1	–	0	4
K9GHNE203315R02	R-2000iB/210F, 210 kg	V7.6310, VW user –	1, 2	0, 1	1	–	1	4
kezorv114470r01rs1kfu1	R-2000iC/210L, 210 kg	V9.1618, VW user –	1, 15	0, 1	1	–	0	5
kemurt131180r01rs1kfu1	R-2000iC/210L, 210 kg	V9.1620, ARGDISPGR02.26062	1, 3, 5, 6, 32	0, 1	1, 2, 3, 4, 32	E1 along X	0	5

The station mixes two controller generations (V7.63 and V9.16), and only kemurt has a VW user version in the backup.

ERROR: UT 2 is used but not set (X, Y, Z, W, P, R are all 0). It is used in folge123 (8 points) and in motn021–025 and motn033. On R01 the same UT 2 is set (X -1.1, Y 0.1, Z 1064.3).
MAKRO980 calls MAKRO941–946 (lines 29–34), but those Makros are not in the backup. Nothing calls MAKRO980, so this is a leftover rather than a runtime error.
MAKRO998 is called 15 times (every Folge), but the backup has only MAKRO998.VR. It is probably a KAREL program, so it could not be checked.
UT 1, UT 2 and UF 1 have no comment.
Mastering of motion groups 3 and 4: REF_DONE = FALSE. They are mastered, but quick mastering is not possible.

UT 1, UT 15, UF 1 and PAYLOAD 1 (170.7 kg, 81 % of rated) are set and plausible. Group 1 is mastered.
UP002 has about 240 point lines, but no Folge calls it. FOLGE071 calls only UP001. Also not called: UP009, UP100, UP106, UP201 and UP901.
FOLGE001 has no PAYLOAD[...] line.
The IP address is empty in the backup. The UTs and UF have no comments.
Group 5 has REF_DONE = FALSE.

All used UTs (1, 3, 5, 6, 32) and UF 1 are set and have names.
Travel track: axis 7 limits are −2050 … +430 mm, and all points lie between −1757.0 and +345.0 mm.
PAYLOAD 3 and 4 ("G2 OT" / "G2 MT", 60 kg each): inertia IX = 0, so the data were probably entered by hand rather than identified.
PAYLOAD 32 ("DS") is 210.0 kg, which is 100 % of the rated payload. It is probably the factory default value; check it. It is used in 4 lines.
UT 2, UF 2 ("BHF 1"), UF 3 ("BHF 2") and UF 6 ("SICK Kal. Platte") are set but no point uses them.
Group 5 has REF_DONE = FALSE.

K9GHNE203315R01 and R02: MAKRO002–014, 072, 073, 076, 077, 084, 085, 102–149 (19 Makros), 512, 513, 900, 980.
kezorv114470r01rs1kfu1: MAKRO040, 064, 065, 067, 069, 512, 520, 521, 523, 524, 604, 900, 919, 947, 957, 967, 977, 980.
kemurt131180r01rs1kfu1: every called Makro exists. For the unused ones, the editor's list was cut off, so I can't give them.

Group 1 is mastered (MASTER_DONE and REF_DONE = TRUE). The robots are mounted on the floor (MOUNT_ANGLE 0).
Software limit switches of J1–J6 are valid:
- R-2000iB (K9robots): J1 ±180°, J2 −60/+76°, J3 −132.04/+230°, J4 ±360°, J5 ±125°, J6 ±360°.
- R-2000iC (kezorv, kemurt): J1 ±185°, J2 −60/+76°, J3 −120.71/+180°, J4 ±360°, J5 ±125°, J6 ±360°.
Every UP called from a Folge exists.

On K9GHNE203315R02, teach or enter UT 2 (compare with UT 2 on R01). Until then, Folge 123 and MOTN021–025 / MOTN033 run with the flange as TCP.
Get a backup that includes MAKRO998 (the KAREL program), or confirm it is a standard VW KAREL program.
On kemurt, check PAYLOAD 32 (210 kg) and run payload identification for PAYLOAD 3 and 4.
On kezorv, decide whether UP002 is still needed. Add a PAYLOAD line to FOLGE001.
Clean up: on the K9robots, delete MAKRO980 or add the missing MAKRO941–946. Remove the unused Makros, UTs and UFs, and add comments to the UTs and UFs on K9and kezorv.
Set REF_DONE for the extra motion groups (K9groups 3/4, kezorv and kemurt group 5).

What I read: the english/*.LS programs of all 4 robots (1588 files including the german copies), plus SYSFRAME.VA, SYMOTN.VA and SYSMAST.VA.
Payload inertia: I checked only IX, not IY/IZ.
Not checked:
- UTOOL_NUM / UFRAME_NUM against each point
- .TP files that have no .LS
- Folge comments
- $MASTER_COUN pulse counts